Sheet Metal Working

Stretch Forming
Sheet metal is stretched and simultaneously bent to achieve shape change

Outline
• Stretch forming
• Automotive stamping processes
• Stretch forming vs. stamping
• Spinning
• HERF
• Superplasticity (2) die is pressed into the work with
• Superplastic forming force Fdie, causing it to be stretched
(1) start of process
• Superplastic forming with diffusion bonding and bent. F = stretching force
• The shape is produced entirely by tensile stretching so the limiting strain is

that at necking.
• It can be thought of as a uniaxial tensile stress condition.
• And the forming limit is reached when the local strain equals ………….
Dr. M. Medraj Mech. Eng. Dept. - Concordia University Mech 421/6511 lecture 10/1 Dr. M. Medraj Mech. Eng. Dept. - Concordia University Mech 421/6511 lecture 10/2
Stretch Forming: steps Stretch Forming: equipment
Loading Pre-Stretching
Release
Rapping
Stretch Forming with ……………. Tool
Stretch Forming: Products Force Required in Stretch Forming
where
F = stretching force
F = LtYf L = length of sheet in direction perpendicular to
stretching
t = instantaneous stock thickness
Yf = flow stress of work metal
Die force Fdie can be determined by balancing vertical force components
Example
Calculate the force required to stretch form a wing span from a sheet of
2219 aluminum having a cross-sectional area of 13x305 mm, a yield
strength of 250 MPa and a UTS of 360 Mpa.
Automotive Stamping Automotive Stamping
10 -11 panels
3 to 5 dies each
~$0.5M each
~$20M investment
Major and minor strains in various regions of an automobile body. The number in
the strain paths indicate the frequency of occurrence.
Stretch Forming vs. Stamping processes Other Sheet metal Forming Processes
Roll Bending:
¾ Stretch Forming Advantages over stamping:
Large metal sheets and plates are
• Tighter tolerances are possible: as tight as 0.0005 inches on large formed into curved sections using rolls
aircraft parts
• ……….. problem with either wrinkling or spring back
• Large and gently contoured parts from thin sheets
¾ Stretch forming Disadvantages over Stamping
Roll Forming:
• Complex or sharply cornered shapes are …………. or ……………
Continuous bending process in
to form
which opposing rolls produce long
• Material removal (blanking, punching, or trimming) requires sections of formed shapes from
secondary operations coil or strip stock
• Requires special preparation of the free edges prior to forming straight rolls final form
partial form
Roll Forming: Example Spinning

Stages in roll forming of a sheet-metal door frame: Metal forming process in which an axially symmetric part is gradually shaped
over a mandrel rotating at high speed using a rounded tool or roller
Conventional Spinning
the rolls may be External Tube Spinning

continuous tube Shear Spinning
shaped as in A or B
High-Energy-Rate Forming (HERF) High-Energy-Rate Forming (HERF)
Processes to form metals using …….. amounts of energy over a
very ……… time Electro Hydraulic Forming:
• Electrical energy is accumulated in
Explosive Forming large capacitors and then released to
Use of explosive charge to form sheet (or plate) metal into a die cavity the electrodes.
• Explosive charge causes a shock wave whose energy is transmitted to • Similar to explosive forming except:
force part into cavity - for the smaller amount of released
energy
• Applications: large parts, typical of aerospace industry
- so, it is good for small parts.
Electro Hydraulic Forming
“Electric Discharge forming”
Electromagnetic Forming:
Sheet metal is deformed by mechanical
force of an electromagnetic field induced
in workpart by an energized coil
- Presently the …………… used HERF
explosive is process
shock wave Electromagnetic Forming
setup detonated forms part - Applications: tubular parts
“Magnetic Pulse forming”
Superplasticity Superplasticity
Superplasticity is the ability of a material to withstand very large Important elements in superplastic properties:
amounts of elongation without the occurrence of necking • Low strain rate (so it is not practical) where
• High temperature C = strength constant
• This property is related to a σ = Cε& m m = strain-rate sensitivity
• Small grain size
predominant mechanism of exponent
• Grain shape
deformation : …………………
sliding Common titanium alloys and several specially processed aluminum alloys
are superplastic. Inconel, specialty stainless steels and several other alloys
• Consequently, it is promoted Superplastic deformation of an aluminum alloy can also be made superplastic.
by a fine microstructure (typically
a mean grain size less than about • Until recently, superplastic forming has only been available at relatively low
twenty microns is required in the strain rates, typically about 1% per min. At this strain rate, about …. is needed
case of metallic alloys). to form an advanced structural component; …….. to be economically effective.
• This property has been used • Superplasticity at higher strain rates, however, can be expected to stimulate
for a long time as a forming broad commercial interest in superplastic forming.
technique for components with • A strain rate higher than …... per minute is considered economically practical.
a particularly …………… shape Such a strain rate would allow the forming of relatively complex structures in
Movement of grains during superplastic
less than three minutes, including set-up time.
deformation of a Pb-Sn alloy
Superplastic Forming Process Superplastic Forming Process
• The SPF process uses superplastic
materials to form very complex sheet metal
parts.
• Dies are heated in a press (900°C for
titanium alloys) and inert gas pressure is
applied at a controlled rate.
• SPF can produce parts that are impossible
to form using conventional methods A superplastically formed
Al-Li alloy component
Benefits...
• Lower Tooling Cost • Elimination of unnecessary joints and rivets
• Reduction of subsequent machining
- As much as …….. lower than stamping dies
• Minimization of materials waste
• Reduced Part Count and Weight
- Replace built up structures with integrally stiffened structures An integrated aluminum structure, for example, traditionally manufactured by
• Greater Design Flexibility welding four pieces of metal, can be manufactured in a single operation through
- Incorporate compound curvatures superplastic forming
- Produce deep draws
- Fabricate very tight bend radii
Superplastic Forming with Diffusion Bonding
• Superplastic Forming can be combined

with Diffusion Bonding to produce a number
of complex SPF/DB structures.
• SPF/DB parts are produced by joining
several sheets in a specific pattern and then Next time:
superplastically expanding the sheets to
produce an integrally-stiffened structure.
Review for sheet metal working

Sheet Metal Working

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Sheet Metal Working

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Stretch Forming

Sheet metal is stretched and simultaneously bent to achieve shape change

• The shape is produced entirely by tensile stretching so the limiting strain is

Stretch Forming: steps Stretch Forming: equipment

Die force Fdie can be determined by balancing vertical force components

Automotive Stamping Automotive Stamping

Roll Forming: Example Spinning

the rolls may be External Tube Spinning

Superplastic Forming with Diffusion Bonding

• Superplastic Forming can be combined

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